Prefabricated vessel construction



March 20, 1945. H. LEE

PREFABRICATED vEssEL CONSTRUCTION Filed June 9, 1944v 2 Sheets-Sheet 1 HARoLuLr-:

Inventor March 20, 1945. H. I EE PREFABRICATED VESSEL CONSTRUCTION Filed June 9, 1944 2 Sheets-Sheet 2 1 afgana/@ HARoLn LEE Patented Mar. 2o, 1.945

UNITED STATES PATENT FFICE e p A 2,371,964 mEF-ABmcAranvEssEL ooNsTnucTloN Hamid' ice, seattle, wash. Application .time 9,1944, serial No. asador This invention. concernsy mar-ine craft and in particular barges, boats, drydocks ,andf 'the like, especially those having iiatwall' portionsx of' 'considera'ole area. Suchmarine craft I shall''refer to. generally as vessels. While my ihveniticlm1is particularly usefulfor suolistru'ctures, italso has:

utilityI for Wallsl or other panels, which may be incorporated in' structures of `dii-ferent types, all' oi which arev intended to be included that 10 More speciiically they invention relates tosti-cli' term.

structures which can bebuilt-of pieta-bricated,`re-L inforcedconcrete panels, and a principal Object of my invention is to facilitate the construction of such individual panels of great strength,- and to render them readily adapted lfor joining to other panels of like construction.

More specifically it is an'objoct toprovide ya' unique reinforcing grid arrangement Aforxrreel'of structural steel shapes, capable' of carryingall the forces to which the panel may be subjected? while in use, and to cast 'concretearound the gridand bond` it to the grid elements." It is a further object to construct the panel margins `so that the edges `of abutting pan-els can be joined to'gether'readily either incoplan'a'r rela tionship or to form an angle. Inmaking suoliz becomey evident 'from a. study of the lfollowing speci-lic description. It will be understood that l various changes proportion; shape andi ara joint an additional Objectis to interconnect by structural members the reinforcing grids of 'the abutting panels, `so that stresses may be transf' mitte'd by way of the structural lsteel skeleton throughoutV the panel assembly 'Withoutreliance on the concrete. A l

Furthermore it is an object, Where abutting panels are joined in coplanar relationship, to form a planar surface on "one side of the panel assembly uninterrupted vby 4grooves or' crevices. In vessel construction such planar side would: face outward.

More: speciiically; it is an object of my inventiontoemploy arein-forci-ng grid of metal struc'- tural shapes for eachpa-nel in which ythe elements are rigidly secured together, such as by welding, before the concrete covering is applied,

and' the structural shapes selected are such asf to interlock with the concrete and to constitute a form in Whicht'lie concrete is cast. It is further desired that elements of` such grid work capable oi transmitting stresses from one panel to the next project well beyond the conc-rete surface of' the iinish'ed panel to be joined to corresponding junction elements of the adjoining panels. f

' Other` objects achieved by details of theparticiul'ar construction which -I prefer to use will rangement of the panels and the elements used in fabricating' them may be made according tol the particular typey of striit'zluire-y in they arel to be used, and the type and degree of. loadingV and other conditions! to which the. panels may besubjected. For. illustrative: purposes my construction fis 'shown inthe. drawingsI asI applied-' to a bargel Figure l is a plan view: ci 'such a barge, showing a: portion of the deck broken away to reveal its internal construction, and Figure 2 'is 'a sidc elevational View or the barge, 'part of is shown in section on line 2 5-l oi Figure Figure 3 is aside elevational View ci' the reinforcing structure oi abutting panels as suoli: structure would appear priorA to pouring the concrete.

Figure 4 isa detail `section-al View of the junchv* tion of an athWar-tship bulkhead, a side and the deck of the barge; yalong line 4*-4 oi liigi-irey l.

Figure-'5 is a detail sectional View of the junctionof' -a side with the'` bottom taken onv line 5-5' ofFigure 2.v

Figure 6 is a vertical section through a different type of athwartships bulkhead," rsl-iowing its connection t'othe bottom and to the deck, and Fig ure 7' is a section through suc-hbu-lkhead on line f Figure 8- is a detail 'sectional view ofthe jun-cs tion of a fore and aft bulkhead. an atnwart'- ships bulkhead, and the deck 'as viewed from line Figure "9l is a detail sectional View of the junetion of thece'ntra-l fore and aft bulkhead with the bottom of the barge, taken online- 9-'`9 of Figure l. Y

Figure" 10 is a fragmentary top' perspective View otone'corn'er of' a panel A'sl'iovt/'i-ng parts 'oi' the concrete broken away to structure.

Figure l1 is a perspective View ofthe i-'unc't'.i'f'cmv reveal the reinforcing n those forming the ends of the barge bottom, which are shown in Figure 2, for example. Also the particular type of construction employed for the panels will'depend upon whether they are to form exterior wall sections l of the barge, such as the bottom, side or deck, or are to be incorporated in an athwartships bulkhead l or a fore and aft bulkhead I I. For panels of all these types the general scheme of fabrication is the same, and the junction construction is generally similar, but details of the panel structure may vary in some degree for panels intended for different locations. Also it will be evident that if such panels are employed for purposes other than barge construction additional modifications may be required.

In Figure is shown in detail the structure of, a typical prefabricated panel, suitable for assembly in the side, bottomor deck of a barge such as pictured. The characteristics of such a panel may, perhaps, best be understood from a descrip-- tion of the fabrication technique and procedure. The first step is to lay upon a flat surface, assuming that the final panel is to be planar, four margin plates 2 to form a rectangular frame. These margin plates are butt-welded together at to complete the frame. Upstanding edgewise from these margin plates, and extending generally centrally lengthwise thereof, are flat bars 2l, the ends of which are welded together at the corners of the frame. Each such bar is also edge-welded to the margin plate 2 on which it stands, so that these flat bars constitute the sides of a shallow box, the bottom of which is formed by the margin plates and by the area bounded by them of the surface on which they are laid.

0n the margin plates, withinthe flat bar rim, spacer blocks 22 are placed, which support, spaced from the margin plates, the ends of bars 23, preferably of channel shape. These channels are arranged at regular intervals parallel to one set of margin plates and perpendicular to the other set. Blocks 22, beneath each end of each channel bar 23, should be of a thickness to locate the bar approximately centrally between the tops of flat bars 2l and the lower surface of the frame formed by margin plates 2. The first channel 23 may overlie one of themargin plates, as shown in Figure l0, and when welded thereto stiffens such edge of the panel. All the channel bars of the entire parallel series are welded to their re spective supporting blocks 22 and their ends are welded to the flat bars 2 I, which they abut. Also, each block 22 is welded to the margin plate on which it rests.

If it is desired that the panel be perfectly plain on both sides, and if it is to besubjected to bending stress only lengthwise of bars 23, these bars alone may afford sufficient reinforcement, because their ends are xedly interconnected through the blocks 22 and margin plates 2 as well as by the flat bars. If the panel is to be used in barge construction, however, for which purpose it is especially intended, it must be stiffened both longitudinally and transversely to withstand bending loads in every direction. For' such purposes an additional series of bars 24, preferably of I-beam section, is superimposed upon channels 23, extending transversely of them. The points of contact of the two series of bars are welded together at to complete the reinforcing grid. In addition the ends of the I-beams 24 are welded to the at bars 2 l which they abut. Such I-beams should have Webs of considerable depth so that the completed panel will have a high section modulus, even though the thickness of the concrete may not be a major portion of the overall panel thickness.

Concrete may now be poured into the box formed by at bars 2l, margin plates 2 and the surface underlying and encompassed by such frame. The concrete may be leveled with the upper edges of the flat bars, such bars serving as a screed, so that the channels 23 may be completely embedded substantially centrally between the surfaces of the concrete slab. It will be appreciated that the concrete set between the channel flanges will lock these .parts positively with the rest of the concrete. Similarly, the lower flanges of I-beams 24 and a small portion of their webs will be embedded in the concrete. After the concrete has set the panel may be lifted from its supporting surface ready for assembly with similar panels in edge to edge relationship.

When panels of the type thus constructed are used to form the side, the bottom or the deck of a barge, such as shown in Figures 1 and 2, for example, they are assembled so that the I-beams 24 extend vertically in the side panels and athwartships in the deck and bottom panels, corresponding to the ribs conventionally incorporated in vessel construction. The channels therefore constitute the longerons of the sides and bottom. In such an installation the concreter itself serves merely as a wall to prevent entrance of the water and to transmit local stresses to the reinforcing bars. Adjoining panels are designed so that, when the edges of their margin plates are welded together at 3 in proper relationship, as illustrated in Figure 3, corresponding grid bars in the several panels are aligned. Such bars, therefore, not only transmit stresses from the concrete to the nearest margin plate of the same panel, but such stresses are distributed from one margin plate to the next,- and thus are absorbed by the entire framework of the hull.

When panels fabricated in the manner described are assembled to form an angle, such as for a corner joint between the bottom and a side of a barge, as shown in Figures 5 and 11, an angular space is left between the margin plates 2 and dat bars 2l of the two panels, which affords access for welding together the abutting edges of the margin plates. A reinforcing angle 4 may be welded to the exterior of such a corner if desired, as shown in Figure 5. A similar space is left within the angle formed by the junction of the deck or the bottom of the barge with a bulkhead or with a side of the barge.

In order to stiften as a whole the structure of a barge such as shown in Figures 1 and 2, at least several athwartships bulkheads l0, and preferably also a fore and aft bulkhead II should be employed. Figure 4 shows a junction of such an athwartships bulkhead with the joint between two side panels l. The bulkhead may be constructed similarly to the side panels, as described above. It is preferred, however, instead of margin plates 2 being flush with the outer surface of the panels, that the corresponding margin plate 26 be located centrally of the bulkhead and received in slots cut in the ends of the channel bars 23, as shown in Figure 4, which channels are readily cut, and which .constitute the sole forming of special jointing means between elements of a given panel. Alternatively two margin plates may be used, being coplanar, respectively, with the opposite sides of the bulkhead and welded to spacer blocks like 22, located on opposite sides of the embedded channels 23 and in turn welded to such channels inthe manner previously described. The single constructionis a lighter one, preferred for interior bulkhead construction. l

Whether one or two margin plates are used for the bulkhead l', the. proper angular relations ship between it `and each. side panel t should be established and maintained. by gusset plates; 2.1 spanning the hollow angle. between the margin plates of the panels. Complemental parts of such gussets may be welded. to the margin plates 2 and liet bars 2-I of the side and bulkhead panels before they are assembled, so that such gusset parts may be. joined by' a single welded seam 28 when they have been brought into abutment by assembly of the panels. The abutting edges ofthe side panel margin plates 2 are welded. at 3,v and a plate 3U spanning this joint may be welded both to the side panel margin plates and to the bulkhead margin plate. 26. As shown in Figure 1l, the spacing between adjacent gussets 21 is more or less arbitrary,'but they should be sufciently close together to prevent any tendency of the abutting margin plates to warp or twist, and to hold the panels in the desired angular relationship to each other. They are readily Iocated by surrounding jigs, at the time themargin plates are laidfoi pouring of the concrete, and either prior to or after the concrete is poured'.

When the bulkhead and side panel joint ls finished it will be seen that the side of the barge is continuous andl uninterrupted by anyl appreciable projection or indentation, because the margin platesare disposed coplanar with the concrete surface on the exterior of the panel I The fact that these corners` are hollow, rather than bei-ng filled with concrete, isy not objectionable, because they are a-mplyA braced to withstand any load to which they maybe subjected, and in particular a transverse bulkhead formsA an effective .backing structure for eachjoint betweenside panels. Rather, it is help-ful, in that it affords ready access for welding in the subsequent: as`r sembly of panels intothe barge.

The junction between the side and bottom panels I, as. shown in Figure 5, is much the Same; as the'structurev at each side of a bulkhead joined head, tozpmake.- it even: stiffer than. the sides or the: barge so that ittl cooperates with the athwartships bulkheads to produce an extremely -rig-id central' structure. To obtain thisfeffect I-beams such vas 24 may be welded to both sides of channels 23- in the vmanner shown .in Figure 7i, to increase the effective thickness of 'the bulkhead', and consequently y'its section modulus, without. a corresponding increase in weight. y

A similar structure may be used in the athwartships bulkheads. aswell, asindicated in Figure 6, particularly if cargo is to be carried within the barge and if the cargo is of al type which may exert. considerable bending: force on. the walls of thehold, such-.ras mightbe occasioned at. timesl byy liquidy cargo. The only l:inference in connecting such a. bulkhead and one 'of` the type show-n in vlliligiure. 4 or vFigure 11- to'y the deck and 'bottom panels is: in the. lgusset plates used. Since in the deck and bottom panels the 1*-b5ea1ns extend athwartships, and have-no .I-beams with which the double vertical I-beams of the bulkhead can abut, the gusset plates are extended in each in' stance to be welded to the ends 'of the bulkhead I-beam webs while 'the corners at the ends of the exposed I-beam:l anges are merely rounded or beveled to nish themneatly.

In the case of the fore and! aft bulkhead, the flanges. of its vertically disposed I-beams 24' would be welded 'to the flanges ot the transverse I-beanis of the floor panels and gusset plates would be welded to the ends of` the I-beam webs and to each other, as. shown in Figure 9.. Because to side panels as shown in Figure 4, and also similar to that at eachv side of an. athwartships bulkhead.. abutting the. bottom of the. barge.. A.

comparison of these three corner constructions may be made readily by reference to Figurey 1l.

ning the angle formed by I-beams thus joined may be welded to their flanges. To afford additional stiffness, if required, diagonalbraces 32'4 may be welded to gusset plates 3l intermediatethe fore and aft bulkhead-II and the sides- -of the barge.

Qrdinarily, since the ath-wartships bulkheads need not be' asV greatly resistant to bending stresses as the fore and aft bulkhead H, if` such is employed, these athwartships bulkheads. are.` made lighter than the otherpanels.y In. fact, it maybe desirable, where. the beam. of the barge is suiliciently great to require a fore. and ait bulktwin I-beams 24 can be used in the fore and aft bulkhead structure, they usually. need vnot be as heavy as the Ibeams used forthe ribx sec.- tions inthe bottom and side panels. In. a barge structure of the type shown,` the bottom panels on opposite sides of the fore; and aft bulkhead may be inclined slightly relative to each other, as shown in Figure 9. Thisis merelya. matter of proper shaping of the gussets 21.

The same.V procedure in general is: followed in connectingy together the panels forming the fore. and aft and athwartships bulkheads at their in,- tersections as in joining the abutting edges of panels at other locations. Thus in. Figure 8` the panels of both the bulkheads I0 and I` l. have `central margin plates 26 instead of margin plates ush with a surface of` the` respective panels. Again gusset plates A21 are welded together at 28 in the fashion previously described and the corners are hollow to afford accessr for rsuch welding operation. vReinforcing platesV are located on opposite sides of one of the margin plate joints. Thus it willv be seen that the. same gen eral arrangement of margin plates, flat bars and gussets all welded together is employed/whether respective Vmargin plates of two,v three or four panels abut.

It will be understood that my method of construction greatly facilitates not only the fabrication of the panels but their assembly, and the finished structure is extremely strong and has a.

stresses, particularly in bending,'are transmitted from the I-beams of a side panel, for example, through the coplanar gusset plates 2l and 3| to the I-beams of a bottom or a deck panel. Within each panel stresses are vequalized between between the longerons and the ribs by reason of their welded interconnection, entirely independently of the concrete except as it transmits stresses locally within each bay of each grid to the grid members encompassing such bay.

It should lbe particularly noted that intricate shaping of the ends of structural shapes is completely eliminated. All vsuch elements are merely cut to length, and welded to adjoining elements,

after proper placement. `The sole exception, 'and this only for greater lightness, consists in the simple slotting of the ends of the channels 23 to receive the single margin plate 26, in the bulk.' head construction; even this may be avoided if dual margin plates are preferred.

All iitting is accomplished by shaping (prior to assembly) of flat, small gusset plates 2l. These, per se, are light, small, and readily hanclled, and can be readily inspected for proper shape. Once assembled in the reinforcing structure, they accomplish a triple purpose; they support and brace the at bars 2l for pouring of concrete; they determine the relative angularity of adjoining panels (fiat, as in Figure 4, or V-shaped, as in Figure 9) during assembly; and they serve to complete the ribs or corresponding skeletal elements, and to transmit stresses throughout all. parts thereof, in the finished barge.

The rounded ends can be similarly formed. longitudinal elements of the stress-bearing structure being preformed to the proper radius, and the Whole being laid o-n a properlycurved, in stead of a'plane, surface.

By proceeding thus, individual panels, each of a standard size to be readily formed and handled, 4can be constructed with a minimum of expenditure of time, expense, and labor, and with a minimum of labor in prefitting, yet may be accurately and quickly assembled. In assembling, each side, bottom, or deck may be assembled complete, and joined to other complete elements, or preferably, the barge may be assembled by placing each panel in its proper place in the whole assembly, and joining it to adjoining panels, to build up the'barge from the relatively few variations of one standard panel.

I claim as my invention:

l. A hollow structure, such as a barge, formed with bottom and side walls, each of which is formed of a plurality of panels edge-joined to each other in the common side wall or bottom, and edge-joined angularly to similar panels in the adjoining bottom or side wall, each such panel comprising a central monolithic slab, a marginal plate projecting in the same general plane from each edge, a reinforcing structure embedded in said slab and structurally integral with said marginal plate, and preformed gusset plates disposed about said slab, in planes transverse to the plane of the marginal plate, and structurally integral with the latter and with the embedded reinforcing structure, the gusset plates of each panel being positioned to match with corresponding gusset plates of adjoining panels, and each by its preformation determining the `relative angularity of adjoining panels, said gusset plates and the marginal plates being joined, as by welding, to complete the panel structure and eventually the barge structure, and

to form, withthe embedded reinforcing structure, a' continuous skeleton structure `capable of assuming all external stresses upon the barge.

2. A hollow structure, such as a barge, formed with bottom, side walls, and interior bulkheads, each of which is formed of a plurality of panels edge-joined to each other in the common side wall, bottom, or bulkheads, and to similar panels in angularly disposed bottom, side walls, or bulkheads, each such panel comprising a central monolithic slab, a marginal plate projecting in the same general plane from each edge, a reinforcing structure embedded in said slab and structurally integral with said marginal plate, and gusset plates disposed about said slab, in planes transverse to the plane of the marginal plate, and structurally integral with the latter and with the embedded reinforcing structure, the gusset plates or" each panel being formed and positioned to match with *corresponding gusset plates of adjoining panels, by such formation determining the relative angularity of adjoining panels, said gusset plates and the marginal plates being joined, as by Welding, to complete, respectively, a continuous skeletal structure and a continuous skin structure, wherein the skeletal structure is capable of assuming all external stresses upon the barge.

3. A structure, such as a barge, formed with bottom and side walls, each of which is formed of a plurality ofV panels edge-joined to each other in the common side wall or bottom, and to similar panels in angularly disposed bottom or side walls, each such panel comprising a central monolithic slab, a marginal plate projecting in the same general plane from each edge, a reinforcing structure embedded in said slab and structirrally integral with said marginal plate to transmit stresses from one edge of the slab to its opposite edge, and gusset plates disposed about said slab, in planes transverse to the plane of the marginal plate, and structurally integral with the latter and with the embedded reinforcing structure, the gusset plates of each panel being formed and positioned to match with corresponding gusset plates of adjoining p'anels, and being joined thereto, as by welding, to complete a continuous skeletal structure capable of assuming all external stresses and of distributing them through the thus-joined panels, the projection of the marginal plates being sufficient to alford'access, in plane and in angled joints, for such joining of the gusset plates, the edges of the marginal plates being disposed, by such joining of the respective gusset plates, for joining, as by welding, tothe edges of the marginal plates of adjoining* panels, to complete a continuous skin structure.

4. A panel for incorporation, with a plurality of similar panels, into a barge or the like, com-k prising a central monolithic slab, a reinforcing structure embedded in such slab and terminating at the edges thereof, a marginal plate overlapping the margins of such reinforcing structure and structurally integral therewith, said marginal plate lying in the same general plane as the slab and projecting therefrom at all sides, and a plurality of gusset plates disposed outwardly from the edges of the slab, in planes transverse to the plane of the marginal plate, and structurally joined to the latter and to the embedded reinforcing structure, each gusset plate being formed Yfor juncture toV asimilar gusset plate of a slab which is adjoining in the complete barge.

5. A panel for incorporation, with a plurality of similar panels, into a barge or the like, corn,-`

prising a central monolithic slab, a marginal plate projecting therefrom at all sides, a reinforcing structure including transverse elements embedded therein and crossed elements at least partly embedded therein, all said elements being structurally joined tov the inner edges of the marginal plate, to transmit stresses across the slab and to define in the slab bays of limited stress, and a plurality of gusset plates disposed outwardly from the edges of the slab, in planes transverse to the plane of the marginal plate, and structurally joined tothe latter and to the elements of the reinforcing structure, each gusset plate being formed for juncture to a similar gussetA plate of a panel which, in the complete structure, is adjoining, thereby to transmit stresses between the reinforcing elements of adjoining panels.v

6. A panel for incorporation, with a plurality of similar panels, into a barge or the like, `comprising a marginal plate disposed in the general,

plane of the panel, an upstanding rim disposed between the inner and outer edges of the marginal plate, a reinforcing structure including crossed stress-transmitting elements extending between opposite sides of said rim, the whole being structurally integrally joined together, as by welding, at substantially all points of contact, a monolithic slab within the rim, embedding the reinforcing structure and the inner edges of the marginal plate, and gusset plates disposed out- 'wardly from the rim, in planes transverse lto the plane of the marginal plate, and structurally integrally joined to both, for juncture to similarly disposed gusset plates of an adjoining slab, thereby to transmit stresses, through the rim, between the reinforcing elements of thus-adjoined panels.

7. A panel for incorporation, with a plurality of similar panels, into a barge or the like, comprising a marginal plate disposed in the general plane of the panel, a rim upstanding about the marginal plate, between its inner and outer edges, transverse structural elements resistant to bending extending between and end-abuttingopposite l sides of said rim, further structural elements resistant to bending crossing said first elements, end-abutting other opposite sides of said rim, and upstanding thereabove, the several structural elements, the rim, and the marginal plate being structurally integrally joined at substan-l tially all points of contact, a monolithic slab disposed within the rim, and embedding the structural elements therewithin, and gusset plates disposed outwardly from the rim, in planes transverse to the plane-of the marginal plate and generally in continuation of structural elements, and structurally integrally joined to the rim and to the marginal plate, for juncture with similarly disposed gusset plates of an adjoining slab.

8. A panel asin claim 7, wherein the webs/of the structural Velements are notched inwardly from their ends, the marginal plate being seated in said notches, and wherein the rim is upstanding at both sides of the marginal plate.

9. A panel for incorporation, with a plurality of similar panels, into a barge or the like; comprising a marginal plate defining' a frame disposed in the general plane of the panel, a central reinforcing structure including crossed transverse elements having reentrant angles,and resistant to bending, each extending between opposite sides of said frame, a monolithic slab embedding said reinforcing structure, and bonded thereto for local stress transmission by the reentrant angles of the several transverse elements, the edges of said slab terminating inwardly of the outer edges of said marginal plate, and means structurally integral with the projecting marginal plate, and with certain of said reinforcing elements, and disposed in prolongation of the latter, to transmit stresses to similar .elements of adjoining slabs when connected thereto.

10. For incorporation in a vessel or the like,

prefabricated panels disposed in edge abutting relationship, each fpanel comprising a concrete 'slab and a metal margin plat'e'bonded to said concrete slab and projecting a substantial distance beyond an edge thereof and coplanar with one surafce of said slab, the adjoiningl margin plates of abutting panelsbeingA butt welded together to produce a joint forming a substantially smooth surface coplanar with the corresponding i surface of the joined panels, unbroken by appreciable indentations or projections.

l1. For incorporation in a vessel or the like, prefa'bricated panels disposed in edge abutting relationship, each panel comprising a concrete slab and a metal margin plate bonded to said concrete slab and projecting a substantial distance beyond an edge thereof and eoplanar with one surface of said slab, the adjoining margin plates of abutting panels being butt welded together to produce a joint forming a substantially smooth surface coplanar with the corresponding surface of the joined panels, unbroken by appreciable indentations or projections, and matching bracing elements disposed at intervals along the opposite face ofthe margin plates of each panel to bridge, when joined, the adjacent edges of the respective slabs, and to transmit stresses therebetween.

12. For incorporation in the houll of a vessel or the like, a panel comprising a reinforcing grid composed of members of structural shape extend-- ing lengthwise and transversely of the vpanel in substantially perpendicularly intersecting rela-` 

